Liquid soap converter



March 3, 1936. A. BOBRICK v LIQUID SOAP CONVERTER Filed NOV. 1'7, 1954oz? gVENT OR.

Patented Mar. 3, 1936 UNITED STATES PATENT OFFICE 21 Claims.

This invention contemplates the provision of an improved method andmeans of producing liquid soap from a concentrated soap base, whereby aVolume of the liquid soap of uniform character and grade may be made ata single operation within the capacity of the apparatus.

To this end I have provided an apparatus which is practically. automaticin character and embodies a water softening receptacle connected with asoap conversion receptacle in which a quantity of soap base inconcentrated form may be held in suspension upon a suitable perviouscarrier, or screen whereby a substantial quantity of the soap may bemaintained in the receptacle below said screen at all times, and meansfor feeding the treated water from the softening receptacle, undercontrol, to the bottom of the conversion receptacle.

My invention contemplates the provision of means for elevating the soapcarrying screen as the level of the liquid rises in the conversionreceptacle so as to constantly present the concentrate to the lighterwater, and means for withdrawing quantities of the liquid soap for usewhile still retaining a substantial volume of the soap in thereceptacle.

It is another object to provide suitable means for mixing a suitablewater softening element, or elements, with the water as it is deliveredto the water receptacle, whereby said elements may be thoroughly mixedwith the water for precipitating the insoluble salts such as calcium andmagnesium, and thereafter, when the water is thoroughly softened,drawing off the water in measured volume and delivering the same to thesoap mixing receptacle.

A further object is to provide a gauge on the water receptacle whichwill not only indicate the level of the water therein but additionally,the quantity of concentrate, or base, necessary to produce given gradesof liquid soap and the volume of water necessary to be softened for suchquantities. Other and more detailed objects of invention will appear asthe description progresses.

In general, it may be understood that in the liquefication of soap it isprimarily necessary to use either distilled or specially treated waterin order to eliminate the calcium and magnesium salts resident in thewater and which, when they come into contact with soap form insolublesoaps and curds and necessarily use up some of the soap base.

When even distilled water is mixed with soap if the anhydrous content ofthe solution falls below a given point the soap will be cloudy, and eventhough the anhydrous content of the solution is subsequently raised, itis impossible to eliminate the cloud without a substantial amount ofprocessing and filtering. After prolonged fil- 5 tering the cloud mayreappear.

I have discovered that by introducing the treated water into the bottomof the conversion receptacle and through a substantial quantity of soapin the bottom of the receptacle, the gradual passage of the waterupwardly through the soap will gradually raise the level of the solutionas the soap base is dissolved and the anhydrous content of the solutionnever falls to a point at which the solution will cloud.

The soap base being carried on a movable pervious element such as ascreen constantly maintains the soap in the lighter solution above thedissolved soap which naturally settles to the bottom of the soapreceptacle, thereby facilitating go the liquefication process.

In the accompanying drawing I have shown a preferred form of apparatusfor carrying out the above and other objects of invention, subject tomodification and elaboration within the scope 25 of the appended claims,without departing from the spirit of my invention.

In said drawing:

Fig. 1 is a perspective View of an assembled liquid soap converterembodying my invention, and partly broken away to show the interior;

Fig. 2 is a sectional elevation of the same on line 22 of Fig. 1;

Fig, 3 is a sectional plan on line 3-3 of Fig. 2;

Fig. 4 is a sectional plan on line 44 of Fig. 2;

Fig. 5 is a sectional View of a connection between the soiteningreceptacle and the water receptacle.

In its preferred and simplest form the apparatus is arranged as acomposite unit with a water receptacle W at the top and a soapconversion receptacle S at the bottom. Said receptacles are separated bya horizontal partition I forming the bottom of the water receptacle.Distilled water may be supplied to the receptacle W, or said receptaclemay receive a supply of water from a service system through a pipe 2adapted to be connected with said system and having a control valve 3from which a pipe 4 extends upwardly through partition I and connectswith a T fitting 5 within the water receptacle W at a point near thebottom of said receptacle.

An outlet pipe 6 extends horizontally from the fitting 5 for directingthe current of water from pipe 2 into receptacle W, and a pipe 1 extendsupwardly in the receptacle from fitting 5 to and connects with a passage8 in a bracket 9 attached to the exterior of receptacle W, as shown inFig. 1.

Bracket 9 has a depending internally threaded neck I0 adapted todetachably support a transparent bottle I I and said bottle is adaptedto contain a suitable water softening or treating element, or elements,for admission to the receptacle W. Passage 8 in bracket 9 connects witha depending tube I2, the lower end of which is disposed at a pointslightly above the bottom of bottle II. Bracket 9 also has a ventpassage I3 which is connected with a short tube I4 extended into thereceptacle W for establishing communication between the interior of thebottle I I and the water receptacle at a point substantially above thebottom of the receptacle. 7

Thus, as water enters receptacle W through pipes 4 and 6 and fitting 5 apartial vacuum is created in tube Twhich induces a flow of the contentsof the bottle II through tube "I, fitting 5 and pipe 6 into receptacle Wfor mixture with the water which enters the receptacle. When the levelof the water in receptacle W reaches a point above the level of the venttube I4 the contents of the bottle II will have been completelyexhausted from the bottle into the receptacle and water will be causedto freely circulate through the bottle, thereby flushing the bottle. Insuch case the bottle will be filled with the treated water from thereceptacle W and the character and extent of the treatment may beobserved through the transparent walls of the bottle for indicating theresults of the treament. Usually a water treating operation requiresabout 24 hours. The precipitated salts resulting from the softeningtreatment may be observed in the bottom of the bottle. 7 V

A predetermined soap mixture'having been desired,'the water is allowedto raise in the receptacle W until the level thereof reaches a point ona gauge G fixed to the exterior of the receptacle W above the bottle IIwhich corresponds to the desired mixture'as indicated on said gauge.Said gauge may be of any suitable type, but, as shown, comprises asimple glass tube having a connection I6 at its bottom with the interiorof receptacle W and a vent at its upper extremity so that water may risein the tube to the level of the water in the receptacle W. Beneaththegauge tube is a block or plate I6 having suitable indicia thereon. Forinstance, on one side of the tube graduations may be provided withlegends indicating different percentages of soap to water, and on theother side of the tube may be provided graduations and legendsindicating different quantities of the soap base required to produceliquid soap corresponding to the percentages shown on said firstmentioned side of the tube G.

Obviously, when the required volume of water has been admitted toreceptacle W the valve 3 is closed and the contents of said receptacleare allowed to stand for such a period of time as may be requiredtocompletely precipitate the hard salts resident in the water and whichare collected in the bottom of the receptacle and also in the bottom ofthe bottle II. Thus, the bottle serves as an indicator for determiningthe results of the water softening operation.

The soap base is deposited in the conversion receptacle S through ahopper H which is hingedly supported at the top and on the front of thesoap receptacle. and the soap falls downwardly into the receptacle andupon a screen B which normally rests upon an internal peripheral supportI! and in a plane substantially above the bottom I8 of the receptacle S.

Screen B has a plurality of floats I9, I9, etc. attached to its upperside and preferably near the corners of the receptacle so that as water,in the manner hereinafter described, enters the receptacle S, the screenwill be gradually elevated in the receptacle with the deposit of soapbase thereon.

' The softened water is delivered, under control, from the receptacle Wto receptacle S through a pipe 20 having an inlet 2| elevated above thebottom I of receptacle W, thence through a needle type valve 22 and apipe 23-which terminates in a coil 24 resting upon the bottom ofreceptacle S and provided with a series of perforations 25, 25,

etc. in its uppermost side, for directing the water upwardly into thereceptacle and through the soap base held on the screen B.

Valve 22 has an operating member 22 externally of and in front of thereceptacle S which may be provided with an indicator for indicating theextent to which the valve is opened and the volume and flow of waterfrom receptacle W to receptacle S. A faucet 26 is provided on the frontof' receptacle S at a level, approximately, of the screen B, for drawingoff the contents of the receptacle S at will, but so positioned as toalways assure a substantial quantity of liquid soap in the bottom ofsaid receptacle below the lowermost level of the screen B and thefaucet.

A drain pipe 21 leads from the bottom of receptacle W to a valve 28 andthence downwardly through receptacle S, thence rearwardly thereof, orotherwise, to a point below said receptacle, for draining-off thecontents of receptacle W.

It will be understood that if the concentrated soap base is deposited inthe receptacle S and water is poured into the receptacle the soap basewill not dissolve unless it is thoroughly agitated for the reason thatliquid soap is heavier than water, and as the base dissolves the heavierliquid soap naturally sinks to the bottom of the receptacle, and a pointwill be reached where at the bottom of the receptacle a saturatedsolution will accumulate and no more of the soap will dissolve.

In the converter herein shown and described, as the water rises in thereceptacle S the floats I 9 raise the screen B with the soap basethereon, thus supporting the base always in the lighter fiuid and, byactual observation, as by means of a miniature converter made of glass,it has been determined that a very perceptible circulation is set up.

The light water issuing from the apertures 25 in the coil 24 rises inthe center and the heavier liquid soap dissolving from the base descendsin the outer portions of receptacle S. The soap base dissolves rapidlywithout agitation so that there is very little, if any, difference inthe anhydrous content of the solution taken from the bottom, top orintermediate portions of the receptacle.

I may attach to the receptacle W a commercial water softener of anysuitable type arranged so that the treated water may be delivered to thereceptacle and, in the manner hereinbefore stated, delivered undercontrol of the valve 3 to receptacle S.

My apparatus and method overcomes many difliculties heretoforeencountered in the production of a liquid soap from a concentrate, someof which are noted as follows:

When'the concentrate is placed in the bottom of the receptacle S andwater is poured thereinto a heavy paste is formed which adheres to thebottom and sides of the receptacle, thereby preventing the water fromgetting under the mass and in complete contact with the soap base. Thesuspension of the soap base above the bottom of the receptacle overcomesthe said difficulty. As the water dissolves the soap, the heavy liquidsoap settles to the bottom and there is finally a saturated solutionwhich will not dissolve any more soap without agitation.

Liquid soap made under any conditions with ordinary water from servicesystems produces a very cloudy liquid soap which must be left to standfor protracted periods of time in order that it may be clarified foruse, hence it has been customary to use distilled Water, only, distilledwater not being always obtainable and requiring unnecessary handling andinconvenience, is troublesome, expensive and requires unnecessary manualeffort in the production of liquid soap, as compared with the automaticmethod and means herein described.

My apparatus is provided with a cleanout valve 29 on the bottom of theconversion receptacle S by means of which the receptacle may bethoroughly flushed and cleaned at intervals.

For the precipitate in the water treating solution, I incorporatecertain materials which, when they come in contact with soap purposelyform a cloud, or precipitate. It is different, though, from the cloudformed when soap is dissolved in water in a dilute solution. Thisprecipitate is quite heavy, and inside of 24 hours settles into thebottom of the lower tank. In settling, it attaches and adheres to anyother very fine precipitate that may be in the soap solution and takesit down with it. This method of clarifying solutions by using colloidalclays, etc., is an old one. I do not use any colloidal clay, butactually form the precipitate in the soap.

When soap base is dissolved in plain softened water, by the ordinarymethods, and with agitators, it is cloudy even though the solution isconcentrated. The cloud, I believe, is formed when the solution is in adilute form. At any rate, after a sufficient lapse of time, usuallyabout six weeks, it will clear. When left standing in a bottle, thesolution has a very cloudy appearance for occasionally as long as twoweeks without any perceptible change, then suddenly the small particlesthat are in suspension seem to come together, forming larger flakes.When these flakes get large enough, they begin to settle, and eventuallya very clear solution results.

I, therefore incorporate the treating solution material that tends tohasten this action, then leave this precipitate in the bottom of thedissolving chamber so that when the water is introduced into the chamberthe circulation tends to raise these flakes off of the bottom anddisperse them through the solution. They being heavy, attach themselvesto any very fine particles in the soap solution and drag them down,clearing the solution in short time.

Ifind that the longer the converter is used and the more precipitatethat forms on the bottom, the clearer the liquid will be and the quickerthe solution will clear.

After the converter has been used three or four times the solution willclarify crystal clear in 48 hours.

What I claim, is:

1. A liquid soap converter comprising a water receptacle and a soapconversion receptacle, a

buoyant carrier in said conversion receptacle for supporting a quantityof soap base in concentrated form, float means associated with and forraising and lowering said carrier as the level of the water is raisedand lowered, and means for feeding water from said Water receptacle to apoint below said carrier in said conversion receptacle, for graduallydissolving the soap base.

3. A liquid soap converter comprising a conversion receptacle, means forfeeding Water thereto under control, a buoyant carrier mounted in saidreceptacle for supporting a quantity of concentrated soap base, floatmeans in said receptacle for gradually elevating the carrier and soapbase in said receptacle as the level of the water is raised therein, andmeans for drawing off the converted soap at a point above the lowermostlevel of said carrier.

4. A liquid soap converter comprising a conversion receptacle, means forfeeding water thereto under control, a vertically movable carrier insaid receptacle for supporting a quantity of concentrated soap base fordissolution in the water, means for elevating said carrier as the waterlevel in the receptacle is raised, means for limiting the a downwardmovement of said carrier so as to provide a space therebelow forcontaining a substantial volume of liquid soap, and means approximatelyat the lowermost level of said carrier for withdrawing the liquid soapfrom the receptacle for use.

5. A liquid soap converter comprising a conversion receptacle, means forfeeding water thereto, a floating carrier said receptacle for supportinga quantity of soap base above the bottom of the receptacle, means forlimiting the downward movement of said carrier to a plane substantiallyabove the bottom of the receptacle, and means for Withdrawing the liquidsoap from the receptacle at a point approximately at the lowermost levelof said carrier.

6. A liquid soap converter comprising a water receptacle, a soapconversion receptacle for supporting a quantity of soap base to bedissolved, means for supplying Water to said water receptacle, means forfeeding water from said water receptacle to said conversion receptacle,and a water treating apparatus connected with said water receptacle andincluding a receptacle for holding a quantity of softening material andconnected with said water supply means whereby said materials Will beintroduced into said water receptacle with the water from said supplymeans.

'7. A liquid soap converter comprising a water receptacle, a soapconversion receptacle for supporting a quantity of soap base to bedissolved, means for supplying water to said water receptacle, means forfeeding water from said water receptacle to said conversion receptacle,and a water treating apparatus connected with said water receptacle andincluding a receptacle for holding a quantity of softening material andconnected with said water supply means whereby said materials Will beintroduced into said water receptacle with the Water from said supplymeans,

said apparatus having an additional connection with said waterreceptacle whereby when the level of water in said water receptaclereaches a point above said additional connection the water will becaused to circulate through said softening receptacle, for flushing thesame.

8. A liquid soap converter comprising a water receptacle, a soapconversion receptacle, means for supplying water from a source of supplyto said water receptacle, means for feeding water from said waterreceptacle to said conversion receptacle, and a water treating apparatusseparately connected with said water supply means and with said waterreceptacle at different elevations, whereby a water softening materialmay be introduced into said water receptacle with the water from saidsupply means and water from the water receptacle. circulated throughsaid apparatus when the water attains a predetermined levelin the waterreceptacle.

9. A liquid soap converter comprising a soap conversion receptacle and awater receptacle, means for supplying water under pressure to said waterreceptacle, means for supplying water from said water receptacle to saidconversion receptacle, a transparent receptacle connected with saidwater receptacle for supporting a quantity of water softening material,said transparent receptacle being connected with said water supply meanswhereby the softening material may be introduced into said waterreceptacle with the water from said supply means, and means above thelevel of said water supply connection for afiording communication withsaid water receptacle, whereby when the level of water in the waterreceptacle attains a predetermined point, water will be caused tocirculate through said transparent receptacle, for indicating thecondition of the water in the water receptacle.

10. A liquid soap converter comprising a soap conversion receptacle, awater receptacle sup-- ported thereon, float supported means in saidconversion receptacle for supporting a quantity of soap base above thebottom of said receptacle, means for feeding water from the waterreceptacle to a point in the conversion receptacle below the soap baseand including an inlet substantially at the bottom of said waterreceptacle, an outlet at the bottom of said conversion receptacle, and avalve for controlling the flow of water to the conversion receptacle.

11. A liquid soap converter comprising a soap conversion receptacle, awater receptacle supported thereon, float supported means in saidconversion receptacle for supporting a quantity 7 of soap base above thebottom of said receptacle,

means for feeding water from the water receptacle to a point in theconversion receptacle below the soap base and including a valve forcontrolling the flow of water to the conversion receptacle, said waterfeeding means including a coil adjacent the bottom of the conversionreceptacle provided with a plurality of outlets on the upper sidethereof for directing the water upwardly.

12. A liquid soap converter comprising a soap conversion receptacle, awater receptacle supported thereon, float supported means in saidconversion receptacle for supporting a quantity of soap base above thebottom of said receptacle including a pervious carrier, means forfeeding water from the water receptacle to a point in the conversionreceptacle below the soap base and including an outlet in saidconversion receptacle below said float means and a Valve for controllingthe flow of water to the conversion receptacle,

and a drain leading from the bottom of said water receptacle andprovided with a valve for opening and closing said drain.

13. A liquid soap converter comprising a soap conversion receptacle, awater receptacle, a floating pervious carrier in said conversionreceptacle for supporting a quantity of soap base above the bottom ofsaid receptacle, means for feeding water from the water receptacle to apoint in the conversion receptacle below the soap base and including aninlet substantially at the bottom'of said water receptacle, an outlet atthe bottom of said conversion receptacle, and a valve for controllingthe flow of water to the conversionreceptacle, and a faucet disposedapproximately at the lowermost level of the soap base, for withdrawingthe liquid soap from the conversion receptacle.

14. A liquid soap converter comprising a water softening receptacle anda soap conversion receptacle, a movable carrier in said conversionreceptacle for supporting a quantity of soap base in concentrated form,and means for feeding water from said water receptacle to saidconversion receptacle and having an outlet at a point below saidcarrier, and a hopper near the top of said conversion receptacle throughwhich the soap basev may be deposited in said conversion receptacle.

15. A liquid soap'converter comprising separate water and conversionreceptacles, a pervious carrier vertically movable in said conversionreceptacle for holding a quantity of soap base, means for feeding waterfrom said water receptacle into said conversion receptacle to pointsbelow said carrier, means for limiting the downward movement of saidcarrier to a plane substantially above the bottom of the receptacle, andfloats attached to said carrier for gradually elevating the carrier asthe water level in the receptacle is raised.

16. A liquid soap converter comprising separate Water and conversionreceptacles, a pervious'carrier vertically movable in said conversionreceptacle for holding a quantity of soap base, means forfeeding waterfrom said water receptacle into said conversion receptacle to pointsbelow said carrier, means-for limiting the downward movement of saidcarrier to a plane substantially above the bottom of-the receptacle, andfloats attached to said carrier for gradually elevating the carrier asthe water level in the receptacle is raised, and a hopper at the top ofsaid receptacle through which a quantity of soap base may be depositedon said carrier.

17. A liquid soap converter comprising separate water and conversionreceptacles,,a pervious carrier vertically movable in said conversionreceptacle for holding a quantity of soap base, means for feeding waterfrom said water receptacle into said conversion receptacle to pointsbelow said carrier, means for limiting the downward movement of saidcarrier to a plane substantially above the bottom of the receptacle, andfloats attached to said carrier for gradually elevating the carrier asthe water level in the receptacle is raised and a faucet on saidreceptacle and disposed approximately at the lowermost level of saidcarrier, for Withdrawing the liquid soap from said receptacle.

18. The process of producing liquid soap from a concentrated soap basewhich consists in gradually feeding a solvent into the bottom of aconversion receptacle, and suspending a concentrate on a floatingpervious carrier in said receptacle,

for gradually subjecting the concentrate to dissolution by the solventas the level of the solvent rises in the receptacle.

19. The process of producing liquid soap from a concentrated soap basewhich consists in gradually feeding a solvent into the bottom of aconversion receptacle, and suspending a concentrate on a floatingpervious carrier in said receptacle, for gradually subjecting theconcentrate to dissolution by the solvent as the level of the solventrises in the receptacle, and drawing off the solution at a pointcorresponding to the lowermost level of said carrier.

20. The process of producing liquid soap from a concentrated soap basewhich consists in feeding water to a receptacle, introducing a softeningelement into the Water as it is so fed, allowing the treated water tostand for a sustained period of time for precipitating the insolublesalts contained in the water, feeding the treated water gradually inregulated volume to a conversion receptacle, supporting a quantity ofsoap base on a floating carrier in said conversion receptacle, forsubjecting the soap base ,to gradual dissolution as the water level israised in the conversion receptacle, and withdrawing the liquid soap ata point substantially above the bottom of said conversion receptacle,whereby the heavier settlings will be retained in the conversionreceptacle.

21. The process of producing liquid soap from a concentrated soap basewhich consists in treating water with elements which, when they comeinto contact with soap, form a solution with a cloudy precipitate,settling the insoluble salts resident therein, feeding the treated waterto the bottom of a conversion receptacle and beneath a suspendedquantity of so'ap base whereby the water is forced upwardly in contactwith the soap base, allowing the solution thus treated to stand for aperiod of time during which the cloudy precipitate of the Water mergeswith suspended detached particles of soap in the solution and causessuch particles to settle to the bottom of the receptacle, therebyproviding a clarified solution for use.

ARTHUR L. BOBRICK.

